EV Program Inspection
Led dimensional tolerance inspection of EV aluminum extrusions and supported PPAP documentation for a Tier 1 automotive program.
What?
8 aluminum extrusion part numbers for a major EV program needed dimensional validation before shipping to the Tier 1 customer for final assembly
Parts had to meet strict OEM tolerances across critical features including profile, bow, twist, and visual quality
A team of 4 was needed to inspect 2,000+ parts within the production timeline
How?
Led a team of 4, directing inspection workflows, tracking order numbers, and logging results to ensure a smooth and organized process across all 8 part numbers
Inspected critical dimensions using OEM-compliant fixtures, GO/NOGO gauges, pin gauges, and taper gauges to check bow, twist, and profile, while also flagging visual defects
Logged dimensional results in Excel, conducted capability studies using optical 3D scans, and maintained control plans and PFMEAs to ensure documentation stayed current with production
Results?
Validated 2000+ extrusion tolerances across 8 part numbers, ensuring all parts were in spec ahead of program shipment
Identified a critical bowing defect on one part number through root cause analysis using an OEM fixture. I then communicated the findings to my manager and production teams to drive corrective actions
Reduced NCR rate by 30% on the affected part following correction action
